Multicomponent corrosion inhibitor mix for film-forming binders to protect metal substrates

Abstract

Corrosion inhibitor mixes comprising multiple salts. One mix includes zinc citrate, zinc oxalate and magnesium phosphate. A second mix includes the same two zinc salts, nickel oxalate and nickel phosphate. Either mix may be added to a film-forming binder such as a polymer suitable for a paint or primer, to inhibit corrosion, especially when used with a metallic substrate. The resulting product of the inhibitor mix and binder is especially useful in inhibiting corrosion when applied to an aircraft surface.

What is claimed is: 
     
         1 . A corrosion inhibitor composition comprising at least two metal polycarboxylate salts and at least one non-lithium metallic phosphate salt. 
     
     
         2 . The composition of  claim 1  wherein the at least two metal polycarboxylate salts are chosen from an anion group comprising citrates and oxalates. 
     
     
         3 . The composition of  claim 2  wherein the at least two metal polycarboxylate salts include zinc citrate and zinc oxalate. 
     
     
         4 . The composition of  claim 3 , furthering including at least one nickel salt. 
     
     
         5 . The composition of  claim 4  wherein the at least one nickel salt is selected from the group comprising: nickel oxalate and nickel phosphate. 
     
     
         6 . The composition of  claim 3  wherein the at least one non-lithium metallic phosphate salt is selected from the group comprising nickel phosphate and magnesium phosphate. 
     
     
         7 . The composition of  claim 5  wherein the nickel salt is nickel oxalate and the composition further includes a fourth salt selected from the group comprising: a nickel phosphate or a magnesium phosphate. 
     
     
         8 . The composition of  claim 6  wherein the non-lithium phosphate salt is magnesium phosphate. 
     
     
         9 . A corrosion protection coating for a metallic surface, the corrosion protection coating comprising the corrosion inhibitor composition of  claim 1  and a binder. 
     
     
         10 . The corrosion protection coating of  claim 9  wherein the binder is film-forming binder. 
     
     
         11 . The corrosion protection coating of  claim 9  in the form of: a paint, a primer, a grease, an oil, a gel, a wax, an elastomer, a sealant, and or a gasket. 
     
     
         12 . The corrosion protection coating of  claim 9 , further comprising coated or uncoated metal particles. 
     
     
         13 . The corrosion protection coating of  claim 12  wherein the metal particles are coated and the coating is a semi-conducting corrosion inhibiting coating. 
     
     
         14 . The corrosion protection coating of  claim 13  wherein the semi-conducting corrosion inhibiting coating is a nanometer scale semi-conducting corrosion inhibiting oxide, the oxide derived from an acidic aqueous solution consisting essentially of, in parts by weight,
 from 0.01 to 22 parts of a trivalent chromium compound, 
 from 0.01 to 12 parts of a hexafluorozirconate, and 
 from 0.01 to 12 parts of at least one fluorocompound selected from the group consisting of tetrafluoroborates, hexafluorosilicates, and hexafluorotitanates. 
 
     
     
         15 . The corrosion protection coating of any of  claim 9 , wherein the metallic surface, includes an aluminum alloy surface. 
     
     
         16 . A corrosion protection coating for a metallic surface, comprising:
 a binder; and   a corrosion inhibitor mix comprising zinc oxalate, zinc citrate, and magnesium phosphate.   
     
     
         17 . The corrosion protection coating of  claim 16  further including metal particles. 
     
     
         18 . The corrosion protection coating of  claim 17  wherein the metal particles are aluminum alloy and coated with a semiconductive coating. 
     
     
         19 . The corrosion protection coating of  claim 18  wherein the binder comprises a resin selected from one or more of the following: epoxy resins, polyesters, polyacrylates, polyurethanes, polyethers, polyaspartic esters, polysiloxanes, isocyanates, mercapto-functional resins, amine-functional resins, amide-functional resins, imide-functional resin, silane-containing resins, polysiloxanes, acetoacetate resins, functional fluorinated resins, alkyd resins, and mixtures thereof. 
     
     
         20 . The corrosion protection coating of  claim 19  wherein the corrosion inhibitor mix consists essentially of zinc oxalate 25-75% by weight of inhibitor mix, zinc citrate 25-75%, and magnesium phosphate 5-30%. 
     
     
         21 . A method of protecting an aluminum alloy comprising at least part of a surface of an aircraft, the method comprising:
 coating the surface with a corrosion protection coating comprising a binder, a corrosion inhibitor mix, and coated aluminum alloy particles that are more anodic than the aluminum alloy surface;   wherein the corrosion inhibitor mix consists essentially of zinc oxalate 25-75% by weight of inhibitor mix, zinc citrate 25-75%, and magnesium phosphate 5-30%.   
     
     
         22 . A method of making a corrosion inhibiting product, the method comprising:
 mixing a corrosion inhibitor mix with a binder, the corrosion inhibitor mix comprising zinc oxalate 25-75% by weight of inhibitor mix, zinc citrate 25-75%, and magnesium phosphate 5-30%;   wherein the binder is selected to form a paint, a primer, a grease, an oil, a gel, a wax, an elastomer, a sealant or a gasket.   
     
     
         23 . A corrosion protection coating for a metallic surface, comprising:
 a binder; and   a corrosion inhibitor mix comprising zinc oxalate, zinc citrate, nickel oxalate and nickel phosphate.   
     
     
         24 . The corrosion protection coating of  claim 23  further including metal particles. 
     
     
         25 . The corrosion protection coating of  claim 24  wherein the metal particles are aluminum alloy and coated with a semiconductive coating. 
     
     
         26 . The corrosion protection coating of  claim 25  wherein the binder comprises a resin selected from one or more of the following: epoxy resins, polyesters, polyacrylates, polyurethanes, polyethers, polyaspartic esters, polysiloxanes, isocyanates, mercapto-functional resins, amine-functional resins, amide-functional resins, imide-functional resin, silane-containing resins, polysiloxanes, acetoacetate resins, functional fluorinated resins, alkyd resins, and mixtures thereof. 
     
     
         27 . The corrosion protection coating of  claim 26  wherein the corrosion inhibitor mix consists essentially of Zinc Oxalate 25-75% by weight, Zinc Citrate 25-75%, Nickel Oxalate 5-30% and Nickel Phosphate 5-30%. 
     
     
         28 . A method of protecting an aluminum alloy comprising at least part of a surface of an aircraft, the method comprising:
 coating the surface with a corrosion protection coating comprising a binder, a corrosion inhibitor mix, and coated aluminum alloy particles that are more anodic than the aluminum alloy surface;   wherein the corrosion inhibitor mix consists essentially of zinc oxalate 25-75% by weight of inhibitor mix, zinc citrate 25-75%, nickel oxalate 5-30% and nickel phosphate 5-30%.   
     
     
         29 . A method of making a corrosion inhibiting product, the method comprising:
 mixing a corrosion inhibitor mix with a binder, the corrosion inhibitor mix comprising zinc oxalate 25-75% by weight of inhibitor mix, zinc citrate 25-75%, and nickel oxalate 5-30% and nickel phosphate 5-30% wherein the binder is selected to form a paint, a primer, a grease, an oil, a gel, a wax, an elastomer, a sealant or a gasket.